Layered Sandwich Structure

ABSTRACT

This homogenized, multilayer sandwich structure has a total bending stiffness. The structure has two external skins each of a material having a modulus, a thickness and a width with contribution to the total moment of inertia. The structure also has a core of a foam material sandwiched between the two external skins, wherein the core has a modulus, a thickness and a width with contribution to the total moment of inertia. The external skins are fixed to the core, the strength of the structure being dependent on the core thickness via cubic power, as well as on the placement of the layers within the structure.

CROSS REFERENCE TO RELATED APPLICATIONS

This divisional application claims the benefit of U.S. utility patentapplication Ser. No. 12/661,948 filed on Mar. 26, 2010.

FIELD OF THE INVENTION

This invention relates to a multilayer sandwich structure. In oneembodiment, the invention relates to sandwich constructions comprisingtwo external skins with a foam core sandwiched between the skins. Theinvention also relates to a Model for Calculation of Stiffness/CostValues for the Structures.

BACKGROUND OF THE INVENTION

Cost effective structures having desirable stiffness are needed. Foamsandwich constructions and methods for generating them are known in theart. The construction includes a central foam layer which is formed ofmaterial selected so that central layer can be a substantially thickspacer contributing to the overall stiffness of the construction. Thematerials for the skins primarily are glass fiber reinforced plastic.The core materials generally are polyurethane foam. But it is possibleto use other materials for both. Planar sandwich constructions such asstraight beams or flat panels are included. The invention may also finduse in relation to curved constructions, such as hulls of boats or tubs.

The invention can be applied to 2-, 3- (and more) layer sheet-likestructures, such as films, walls and other types of ‘physical barriers’,ranging from flexible to rigid, whereby the unlimited range of theindividual layer thicknesses, their moduli as well as the costs can beused as input parameters.

SUMMARY OF THE INVENTION

This invention offers an analytical model for calculation of multilayersheet bending stiffness in relation to the total materials cost. Themodel can be applied to 2-, 3- (and more) layer sheet-like structures,such as films, walls, and other types of ‘physical barriers’, rangingfrom flexible to rigid, whereby the unlimited range of the individuallayer thicknesses, their moduli as well as the costs can be used asinput parameters. The result is either a value of the total bendingstiffness of a multilayer structure or the ratio of the total bendingstiffness to cost.

A preferred embodiment results in a homogenized, multilayer sandwichstructure wherein the structure has a total bending stiffness. Thestructure has two external skins each of a material having a modulus, athickness and a width with contribution to the total moment of inertia.The structure also has a core of a foam material sandwiched between thetwo external skins, wherein the core has a modulus, a thickness and awidth with contribution to the total moment of inertia. The externalskins are fixed to the core, the stiffness of the structure beinggreatly dependent on the composite thickness, via cubic power, as wellas on the placement of the layers within the structure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of the foam sandwich structure of this invention.

FIG. 2 is a side view of a multilayer sandwich structure of thisinvention.

FIG. 3 is a schematic representation of homogenized approach forcalculation of the bending stiffness of this invention for a 3-layerstructure.

DETAILED DESCRIPTION OF THE INVENTION

This invention offers an analytical model for calculation of multilayersheet bending stiffness in relation to the total materials cost. Themodel can be applied to 2- or 3-(and more) layer sheet-like structures,such as films, walls and other types of ‘physical barriers’, rangingfrom flexible to rigid, whereby the unlimited range of the individuallayer thicknesses, their moduli as well as the costs can be used asinput parameters. The result is either a value of the total bendingstiffness of a multilayer structure or the ratio of the total bendingstiffness to cost.

FIG. 1 is a side view of the foam sandwich structure of this invention.FIG. 1 shows structure 10 including skin 12, skin 14 with foam layer 16sandwiched therebetween.

FIG. 2 is a side view of multilayer sandwich structure of thisinvention. FIG. 2 illustrates an example of multilayer sheet structure10 of n-layers.

For such a multilayer structure, the total bending stiffness (S_(T)) isa complex function of each layer's modulus (E_(i)) and its contributionto the moment of inertia (I_(i)), which is defined by the layerthickness and its location in the structure (as governed by h_(i)):

$\begin{matrix}{S_{T} = {{\sum\limits_{i = 1}^{n}\; S_{i}} = {{\sum\limits_{i = 1}^{n}\; {E_{i} \cdot I_{i}}} = {{E_{1}{\sum\limits_{i = 1}^{n}\; {\frac{E_{i}}{E_{1}}I_{i}}}} = {E_{1}{\sum\limits_{i = 1}^{n}\; {n_{i}I_{i}}}}}}}} & {{Eq}.\mspace{14mu} (1)}\end{matrix}$

Where:

$n_{i} = \frac{E_{i}}{E_{1}}$

is the ratio of the modulus of the i^(th) layer to the reference (i=1)layer

Where:

$\begin{matrix}{I_{i} = {\frac{{Wn}_{i}h_{i}^{3}}{12} + {{Wn}_{i}{h_{i}\left( {r_{i} - R} \right)}^{2}}}} & {{Eq}.\mspace{14mu} (2)}\end{matrix}$

Where:

$R = \frac{\sum\limits_{i = 1}^{n}\; {n_{i}h_{i}r_{i}}}{\sum\limits_{i = 1}^{n}\; {n_{i}h_{i}}}$

is a neutral axis of a composite layer

And:

$r_{i} = {{\sum\limits_{i = 1}^{i - 1}\; h_{i}} + {\frac{1}{2}h_{i}}}$

is a distance from the reference layer to the mid-plane position of thei^(th) layer

And W is the composite width and h_(i) is thickness of the i^(th) layer.

Under bending conditions, there will always be a neutral axis definingthe compression-tension interface. For homogeneous materials (allconstituents have the same, single modulus; left hand side image) theneutral axis would be positioned in the very middle of the structure,but for a non-homogeneous (multiple layers have different moduli, righthand side image, below) there will be a shift in the position of theneutral axis resulting from disparity in both the modulus as well as theplacement of that layer.

In a homogeneous structure the top and bottom areas are equal. In anon-homogeneous structure, the top and bottom areas are not equal.

For a multilayer structure under bending conditions, the neutral axislocation can be calculated based on the information about the layers'modulus, size and location. Cubic power is defined in the aboveequations.

FIG. 3 shows the “homogenization” approach we employed to arrive at themodel equation for stiffness calculation. FIG. 3 shows layers ofdifferent moduli referenced to (or represented by) one of the layers.The example depicts a bottom layer as a reference layer with modulus E₁.The result of the calculation of the bending stiffness would beidentical should any other layer within the layered structure be chosenas a reference layer. The layer homogenization is achieved via changingthe width of the i^(th) layer by a multiplier n_(i) calculated as aratio of that layer's modulus to the modulus of the reference layer.

The left side of the equation shows a non-homogeneous multilayerstructure wherein the layers have the same width. The right side of theequation shows a homogenized multilayer structure wherein the width of alayer is changed by a multiplier n_(i) calculated as a ratio of thatlayer's modulus to the modulus of the reference layer.

The homogenization allows for direct application of equations (1) and(2), so that the total stiffness of the multilayer structure (S_(T)) iscalculated.

The total cost of the multilayer structure is then calculated as a sumof products of the individual layer thicknesses with their respectivecosts:

Cost=h·[j·C ₃+(1−j)(1−f)·C ₂+(1−j)f·C ₁];   (3)

Where j and f are multipliers (from zero to unity) used to represent thefraction of the thickness of the individual layers in the multilayerstructure.

Finally, the Stiffness to Cost ratio can be calculated directly asS_(T)/Cost.

The analytical model provides reliable means for prediction of thestiffness of multilayer structures in relation to the materials costwithout the need to manufacture the representative prototypes. This isachieved by utilizing the “homogenization” approach whereby a layer of agiven modulus and given width is represented through a modulus (andwidth) of a reference layer within the multilayer structure, having anew width calculated through a multiplier, a ratio of that layer'smodulus to the modulus of the reference layer.

The method of forming the foam sandwich construction may vary widely. Inparticular the constructions are built up generally in a female mold.

The general basic principle for laying up is first to apply a “gel” coatto the polished surface of the mold. This then is followed with a lay-upof a first skin, for example of glass reinforced plastics, to aspecified thickness. Foam material then is applied. Onto the foam isapplied further glass cloth and resin. The foam material suitably isexpanded polyurethane that may be elastomeric.

The glass cloth can be: (a) a chopped strand mat of glass fibers; (b) awoven roving of glass fibers; (c) a woven cloth of glass fibers; andcombination thereof.

For example, in hull shapes of boats, the strips of foam material areapplied to wet resin such as polyester, polyether, or epoxy resin andprovided that the width of the strip of the foam material is limited,the foam material will remain in intimate contact with the resin andbecome securely bonded to it without voids, without use of externalholding down arrangements. Alternatively, the skin may be allowed to setand the strips of foam may be bonded together using further resin.

In accordance with foam sandwich technology the introduction of a foaminterlayer should result in a reduction of the required resin and glasscontent with a reduction in labor time for applying the latter and soone object might be seen as to endeavor to lay up the foam in a time notmore than the time saved by reducing the glass/resin content.

The above detailed description of the present invention is given forexplanatory purposes. It will be apparent to those skilled in the artthat numerous changes and modifications can be made without departingfrom the scope of the invention. Accordingly, the whole of the foregoingdescription is to be construed in an illustrative and not a limitativesense, the scope of the invention being defined solely by the appendedclaims.

We claim:
 1. A homogenized, multilayer sandwich structure wherein thestructure has a total bending stiffness comprising: two external skinseach of a material having a modulus, a thickness and a width withcontribution to the total moment of inertia; a core of a foam materialsandwiched between the two external skins, wherein the core has amodulus, a thickness and a width with contribution to the total momentof inertia; and wherein the external skins are fixed to the core, thestrength of the structure being mainly dependent on the core thicknessvia cubic power and the placement of layers within the structure.
 2. Astructure according to claim 1 further comprising: the core being areference layer; and wherein layer homogenization is achieved viachanging the width of skins by a multiplier (n,g) calculated as a ratioof the skins modulus to the modulus of the reference layer.
 3. Ahomogenized, multilayer sandwich structure wherein the structure has atotal bending stiffness (S_(T)); wherein S_(T) is a complex function ofeach layer's modulus (Ei) and each layers contribution to a moment ofinertia (I_(i)); wherein I_(i) is defined by the thickness of a layer,the layers location in the structure and the width of the layer; whereinlayers of different moduli are represented by a reference layer (E₁);and wherein layer homogenization is achieved via changing the width of alayer by a multiplier calculated as a ratio of a layer's modulus to themodulus of the reference layer.
 4. A structure according to claim 3wherein: $\begin{matrix}{S_{T} = {{\sum\limits_{i = 1}^{n}\; S_{i}} = {{\sum\limits_{i = 1}^{n}\; {E_{i} \cdot I_{i}}} = {{E_{1}{\sum\limits_{i = 1}^{n}\; {\frac{E_{i}}{E_{1}}I_{i}}}} = {E_{1}{\sum\limits_{i = 1}^{n}\; {n_{i}I_{i}}}}}}}} & {{Eq}.\mspace{14mu} (1)}\end{matrix}$ Where: $n_{i} = \frac{E_{i}}{E_{1}}$ is the ratio of themodulus of the i^(th) layer to the reference (i=1) layer
 5. A structureaccording to claim 4 wherein: $\begin{matrix}{I_{i} = {\frac{{Wn}_{i}h_{i}^{3}}{12} + {{Wn}_{i}{h_{i}\left( {r_{i} - R} \right)}^{2}}}} & {{Eq}.\mspace{14mu} (2)}\end{matrix}$ Where:$R = \frac{\sum\limits_{i = 1}^{n}\; {n_{i}h_{i}r_{i}}}{\sum\limits_{i = 1}^{n}\; {n_{i}h_{i}}}$is a neutral axis of a composite layer